Low-Voltage Alternating Current-Based Led Light With Built-In Cooling And Automatic Or Manual Dimming

ABSTRACT

A low-voltage alternating current-based LED light with built-in cooling and automatic or manual dimming. As it is self-cooled with fan failure protection, the light can be safely run in conditions that are near-hostile to its operation, with little possibility of damage. The light is movable along the XY axes of a grid system and can be either fixed in position in the Z axis or can be movable up and down the Z axis. The light can be equipped with either manual dimming using a standard potentiometer, or with automatic dimming via sensors and local network connectivity. The device prevents line-voltage electric shocks as the input voltage is low-voltage AC; in embodiments, about the same voltage as a doorbell, and the input current is 3 A. The device is also self-cooled, and will shut down if its fan is not running so as to prevent thermal overloads.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is related to U.S. patent application Ser. No.15/068,604, filed on Mar. 13, 2016, bearing attorney docket no. HIRT0004and entitled “Hanging Three Dimensional Grid System for Lighting, Data,and Power,” the entirety of which is incorporated herein by thisreference thereto.

BACKGROUND

Technical Field

The present device relates to hydroponic LED lighting.

Background

For many years hydroponic and other farmers and growers of flora haveused indoor lighting, with some using specialized growing techniques toimprove their yield per square foot. Most of those growing techniquesare based on “even lighting,” lighting which shines equally bright overall hydroponic areas.

However, not all flora grows at the same rate, and not all branches ofone plant grow at the same rate. Some flowers and plants grow faster,and can thus dominate the indoor lighting scenario, which can bedisastrous for those plants and flowers that do not grow as fast—truly acase of “only the strong survive”. A small difference in plant or flowerheight can easily result in much more light reaching the taller plantsand flowers, and far less reaching the lower ones due to the inversesquare rule, light blocking and shadows.

SUMMARY

A low-voltage alternating current-based LED light with built-in coolingand automatic or manual dimming. As it is self-cooled with fan failureprotection, the light can be safely run in conditions that arenear-hostile to its operation, with little possibility of damage. Thelight is movable along the XY axes of a grid system and can be eitherfixed in position in the Z axis or can be movable up and down the Zaxis. The light can be equipped with either manual dimming using astandard potentiometer, or with automatic dimming via sensors and localnetwork connectivity. The device prevents line-voltage electric shocksas the input voltage is low-voltage AC; in embodiments, about the samevoltage as a doorbell, and the input current is 3 A. The device is alsoself-cooled, and will shut down if its fan is not running so as toprevent thermal overloads.

The device prevents line-voltage electric shocks as the input voltage islow-voltage AC; in embodiments, about the same voltage as a doorbell,and the input current is 3 A. The device is also self-cooled, and willshut down if its fan is not running so to prevent thermal overloads.

BRIEF DESCRIPTION OF THE DRAWINGS

Various other objects, features, and attendant advantages of the presentdevice will become more fully appreciated as the same becomes betterunderstood when considered in conjunction with the accompanyingdrawings, in which like reference characters designate the same orsimilar parts throughout the several views, and wherein:

FIG. 1 shows an assembled view of a z-axis-fixed light;

FIG. 2 shows an assembled view of a z-axis-movable light;

FIG. 3 shows an exploded view of a fixed, manually-dimmed light;

FIG. 4 shows an exploded view of a movable, manually-dimmed light;

FIG. 5 shows a diagram of a manually-dimmed PCB board;

FIG. 6 shows a block diagram of the manually-dimmed light electronics;

FIG. 7 shows an exploded view of a fixed, automatically-dimmed light;

FIG. 8 shows a diagram of an automatically-dimmed PCB board;

FIG. 9 shows a block diagram of the automatically-dimmed lightelectronics;

FIG. 10 shows an exploded view of a strap-hanging device for a movablelight;

FIG. 11 shows an exploded view of a strap take-up device for a movablelight;

FIG. 12 shows an exploded view of a strap connection feature for a themovable light;

FIG. 13 shows an exploded view of a light sensor;

FIG. 14 shows a assembled light sensor and hanging mechanism assembly;

FIG. 15 shows the assembled light sensor attached to a plant;

FIG. 16 shows a block diagram of the light sensor for theautomatically-dimmed lights;

FIG. 17 shows a top-level display of the automatic dimming application;

FIG. 18 shows a light management display of the automatic dimmingapplication;

FIG. 19 shows a sensor management display of the automatic dimmingapplication;

FIG. 20 shows a setup display of the automatic dimming application;

FIG. 21 provides a functional block diagram of a light control softwareprogram; and

FIG. 22 provides a functional block diagram of a sensor control softwareprogram.

DEFINITIONS

“CPU” shall be defined as either a microprocessor, or a microcontroller,or a programmable logic controller, or as some combination of one ormore of the above-listed components in a configuration that will runsoftware program instructions;

“Disk” shall be defined as the solid-state disk drive(s) of any formfactor, including microSD cards, SD cards, compact flash cards, et al,that is mounted on the printed circuit board or otherwise inside thedevice and is/are thus included within the device;

“LED” shall be defined as any type of light emitting diode;

“Non-volatile memory” shall be defined as either the electronicallyerasable programmable rewriteable memory contained within the CPU orotherwise within the device, for example, EEPROM, or FLASH memory;

“Read from disk” shall be defined as the combination of softwarecommands that initiate the read command(s) to the disk and wait forit/them to complete;

“Read from nonvolatile” shall be defined as the combination of softwarecommands that initiate the read command to EEPROM or FLASH and wait forit to complete;

“VDD” shall be defined as the input voltage of an integrated circuit ordiscrete silicon component;

“Write to disk” shall be defined as the combination of software commandsthat initiate the read and write command(s) to the disk and wait forit/them to complete; and

“Write to nonvolatile” shall be defined as the combination of softwarecommands that initiate the write command to EEPROM or Flash and wait forit to complete.

DETAILED DESCRIPTION

A low-voltage alternating current-based LED light with built-in coolingand automatic or manual dimming. As it is self-cooled with fan failureprotection, the light can be safely run in conditions that arenear-hostile to its operation, with little possibility of damage. Thelight is movable along the XY axes of a grid system and can be eitherfixed in position in the Z axis or can be movable up and down the Zaxis. The light can be equipped with either manual dimming using astandard potentiometer, or with automatic dimming via sensors and localnetwork connectivity. The device prevents line-voltage electric shocksas the input voltage is low-voltage AC; in embodiments, about the samevoltage as a doorbell, and the input current is 3 A. The device is alsoself-cooled, and will shut down if its fan is not running so as toprevent thermal overloads.

In embodiments, the device is comprised of: a light which itself iscomprised of many components; and a fixing mechanism.

In embodiments, the light may include:

-   -   one or more electronic circuit(s) that first rectify an        appropriate AC low-voltage input to DC voltage, then using        voltage regulation circuitry drop the DC voltage down to various        lower DC voltages; specifically, the proper DC VDD for the CPU,        the proper DC VDD for the fan circuitry, and between zero volts        and an appropriate maximum DC voltage for the specific LED in        the embodiment;    -   one or more of a plurality of cooling mechanisms, such as one or        more fans; and    -   one or more of a plurality of heat removal systems, such as one        or more heat sinks.

The fixing mechanism may be either a ¼″ hex head bolt or its metricequivalents for attachment to a hanging mechanism in fixed Z axisembodiments, or a strap hanging mechanism that contains a ¼″ hex headbolt for attachment to a hanging mechanism in movable Z axisembodiments, or other embodiments that contain a hex head bolt forattachment to a hanging mechanism and provide both fixed and movable Zaxis functionality.

In combination with the attached drawings, the technical contents anddetailed description of the present device are described hereinafteraccording to a number of embodiments, but should not be used to limitits scope. Any equivalent variation and modification is covered by theclaims of the present device.

Referring now to FIGS. 1-20, the components of the low-voltagealternating current-based LED light with built-in cooling and automaticor manual dimming device are shown.

In FIG. 1 an embodiment of the device shows the two major components ofthe device can be seen: the light itself 1 and the fixing mechanism, thefixed Z axis fixing mechanism, a ¼″ hex head bolt or its metricequivalent, 2.

In FIG. 2 another embodiment of the device shows the light configuredfor a movable Z axis embodiment hung from a strap 3 along with multiplecomponents of the fixing mechanism: the strap takeup reel 4 takes upexcess Z axis strapping, and the strap grid hanging mechanism 5 connectsthe strap to the previously described grid via it's ¼″ hex head bolt ormetric equivalent 2.

In FIG. 3, an embodiment of a manually dimmed light whose Z axis isfixed are shown. In the embodiment shown, a front cover 6 houses:

-   -   a round piece of plain glass, a lens, or collimator 7; and    -   an LED 9.

In embodiments, an LED 9 may be mounted on a heat sink 10 which may beattached to a cooling fan 11, and the heat sink 10 may be covered with aheat sink shield 12 that may be attached to the inside front cover 8 andthat in turn may be attached to the front cover 6. In this embodiment, aPCB 16 is mounted on the back cover 14, its heat sinks are surrounded byheat sink cooling airflow guides 15, it is covered by a dimmer cover 17,and the back cover in turn is mounted on a main light cover 13. Apotentiometer knob 19 is mounted on the PCB 16 potentiometer shaft,which indicates that this light is manually dimmed.

The inside front cover 8 prevents light and hot air from escapingbackwards, while the heatsink shield 12 prevents damage from occuring tothe heatsink.

In an embodiment shown in FIG. 3, a fixative mechanism for a light thatis fixed along the Z axis may include a fixed light cord relief spacer19 and a ¼″ hex head bolt or its metric equivalent 2.

In FIG. 4, the components of an embodiment of a manually dimmed lightmovable along the Z axis are shown. In the embodiment shown, all of thecomponents of the light that are unrelated to Z axis movability are thesame as those for the embodiment shown in FIG. 3. The difference betweenthe embodiments of FIGS. 3 and 4 lies in the light tilting guide spacingblocks 20 and the light tilting guide 21. In FIG. 4, the light-tiltingguide spacing blocks 20 provide spacing for the light tilting guide 21as the light tilting guide 21 is wider than the light, because thediameter of the light tilting guide is chosen to maintain the center ofgravity of the light at the same distance in a 180-degree semi-circle sothat the light tilts around the center of gravity and remains in achosen position, regardless of light angle.

FIG. 5 provides a pictorial representation of an embodiment of thelight's electronic circuitry PCB board:

-   -   an input power connector 22 brings in 36 VAC to a voltage        regulator 23 mounted on one of a pair of heatsinks 24;    -   a connector 25 is connected to a thermistor mounted on a        heatsink 24 on which a voltage regulator 23 is mounted;    -   a connector 26 is connected to a thermistor mounted on another        heatsink 24 on which an FET 30 is mounted;    -   a connector 27 is connected to a thermistor mounted on the        light's LED heatsink (10 in FIGS. 3 and 4);    -   a CPU 28;    -   a potentiometer 29 varies the voltage to the LED;    -   a connector 31 is the regulated, dimmed output voltage to the        LED (9 in FIGS. 3 and 4); and    -   a three-conductor connector 32 for a fan, as the fan reports        back RPM on conductor 3.

In FIG. 6, a block diagram showing interaction of the components of thelight's electronic circuitry with each other is shown. The 25 VAC inputsource 41 is fed into a full-wave rectifier 23 mounted on its heatsink24 and emerges as ˜35 VDC due to the rectifier's output voltageconversion of 1.414 times the input voltage. In embodiments, the ˜35 VDCbus connects to:

-   -   a 3.3 VDC regulator 33 that creates a proper VDD for the CPU 28        fed in via the VDD pin 35 of the CPU;    -   a 12 VDC regulator 40 for the fan 11 which is a 12 VDC device;        and    -   a 0-32 VDC regulator 45 for the LED.

In the embodiment shown, the thermistors 42 43 44 mounted on theheatsinks 24 24 10 report the temperature as an analog voltage orcurrent to the CPU via the ADC subsystems 39 of the CPU 29 whose programcode then compares the termistor input and determines the hottestcomponent, at which time the program code then determines the proper fanspeed to cool this hottest component and sets its PWM subsystem 38 sothat the fan 11 runs at sufficient speed to cool the hottest component.

In the embodiment shown, the dimmer potentiometer 29 is amanually-turned control that changes the output voltage from the voltageregulator 45 that is fed into the LED's FET 46, thus providing varyinginput voltage to the LED, thus providing dimming.

In FIG. 7, the components of an embodiment of an automatically dimmedlight that that are unique to the automatically-dimmed light are shown.In the embodiment shown, they consist of: unique circuitry, and thus aunique PCB board 46; and an up/down momentary switch, 48, which givesthe user the ability to manually adjust the light's dimming.

In FIG. 8, the components of a PCB board of an automatically dimmedlight that are unique to the automatically dimmed light are shown: anintegrated circuit 50 that is, in various embodiments, a common localnetwork interface that may communicate with the application describedbelow, and another integrated circuit 52 is a digital potentiometer,whose resistance value is set by the CPU according to the application.

In FIG. 9, the components unique to an electronic circuit that supportsan automatically dimmed light are shown in an embodiment:

-   -   the CPU contains new subsystems, an I2C subsystem 54 and an SPI        subsystem 56;    -   there is a single-pole, double-throw momentary on-off-momentary        on switch 48;    -   there is an integrated circuit 58 that supports communications        across, in embodiments, common local networks using their        network protocols; and    -   there is a digital potentiometer integrated circuit 60 which        accepts commands from the CPU to set the output voltage, and        thus replaces the manual dimming potentiometer.

In FIG. 10, the components of an embodiment of a fixative mechanism thatsecures an embodiment of a light that is movable in the Z axis areshown: the grid clamp connection bolt 2 is shown at the top, along whicha spacer 64 and the base of a hanging clamp that rotates 62 are affixed,and the two components are tightened against the grid clamp via a knob66. Affixed to the base of the rotating hanging clamp by two screws 70and two nuts 72 are the clamp 68 and its pressure plate 74, with saidpressure plate applying pressure to the strap 80 via two screws 76 andnuts 80.

In FIG. 11, the components of an embodiment of a strap take-up reel areshown. The strap:

-   -   enters through one slot entry in the shaft cover 86;    -   passes through the shaft 88; and    -   exits the takeup reel through the other antipodally-positioned        slot entry in the shaft cover 86.

In the embodiment shown, the shaft is affixed to the takeup reel sides84 and handles 82 via splines in the shaft 88; the splines cause allparts of the takeup reel to turn at the same time, and since the strapis ‘trapped’ in the takeup reel shaft and shaft cover, when the takeupreel is turned via the handles 82, the strap winds around the shaftcover 86; the takeup reel is prevented from unrolling all the strappingit has taken up via a pin 90 that is inserted along an axis parallel tothe axis of rotation of the takeup reel, which is the axis of the shaft88; and the pin 90 must pass through both takeup reel sides 84 to ensurethat it is securely in-place and thus the strapping will not unroll.

In FIG. 12, an embodiment of a mechanism which connects to the loose endof the strap to a light that is movable in the Z axis is shown. Theloose end of the strap is the part of the strap that is not secured tothe grid. In the embodiment shown, the mechanism consists of a straphanging clamp, 68, that is connected to the strap 80 via a pressureplate 74 which is tighted using screws 76 and nuts 78, that is alsoconnected to the light tilting guide 21 which is mounted on body of thehanging light and attached via screws 70 and nuts 72. In embodiments,the light guide clamp body 92 traps the light tilting guide 21 between apressure plate 96 and a light guide pressure adjusting mechanismcomprised of a knob 66 affixed to the end of a machine screw 94. In theembodiment shown, once the desired angle of tilt has been realized, theuser may turn the knob 66 clockwise to apply pressure to the lighttilting guide, which is trapped between the screw 94 and the pressureplate 96.

In FIG. 13, the components of an embodiment of a light measurementsensor mechanism are shown. The electronics (see below) and a powersource, such as a battery or a power supply, are placed in a container98 in such a manner so as the photocell is on the top and the photocellis covered by a translucent dome 116 that lets light in but keepsforeign objects out. The container 98 is affixed to a plate 118 that inturn is affixed to an arm 104 via a screw 112 and a wing nut 114 in sucha manner that allows the container 98 to rotate in the YZ axes. The arm104 is affixed to one half of a clamp 110 and secured by a screw 108whose axis is orthogonal to the Z axis and whose threaded portion isembedded in the arm 104.

In embodiments, the other half of the light measurement sensor mechanismclamp 110 is affixed to another arm 104 via another screw 108, and onthe arm of this second half of the clamp are affixed a counterweight 106via another screw 112 and another wing nut 114. In embodiments, thecounterweight's weight and moment are chosen so that movement along theYZ axes causes the moment of the weight to shift along the YZ axes,which gives the user the ability to balance out the stress along the XYaxis on the light measurement sensor's clamped axis, which is thevertical Z axis.

In FIG. 14, an embodiment of the light measurement sensor is clamped toa 1 mm wire that hangs down from a grid clamp. The counterweight isadjusted so as to produce zero stress along the wire's XY axes, thuspreventing the wire from bending, and the embodiment of the lightmeasurement sensor is positioned vertically along the 1 mm wire near thetops of plants, so as to measure the actual amount of light landing onleaves of the plant.

In FIG. 15, a light measurement sensor is clamped to the stalk of aplant. The counterweight is adjusted so as to produce zero stress alongthe plant's XY axes, and in the embodiment shown the light measurementsensor is affixed to the plant in such a manner that its Z axis positionis at the same height as a nearby leaf, so as to measure the actualamount of light landing on the leaf of the plant.

In FIG. 16, the block diagram of an embodiment of the light measurementsensor is shown. In embodiments, the device is powered by a 3.3 VDCpower source 126 which can be a plurality of one of:

-   -   a non-rechargeable battery or power cell;    -   a rechargeable battery or power cell; and    -   an AC-based power supply that outputs 3.3 VDC.

In the embodiment shown, as the input voltage can fluctuate, a 3 VDCvoltage regulator 128 ensures we have sufficient voltage to sense, andthe regulated 3 VDC powers the input voltage VDD pin 132 of a CPU thatcontains an I2C subsystem 138 and an ADC 134. The photocell 130 is avariable resistance device whose resistance changes based upon theamount of light landing upon it and thus does not need power. As thelight levels vary, the resistance of the photocell 130 varies and thusthe analog voltage flowing across the pin of the ADC 134 changes. Inembodiments, the CPU sets a timer so that it senses the analog voltageperiodically, for example, one second intervals, and during these CPUtimer-controlled intervals the CPU broadcasts the measurement from thephotocell via any one of a plurality of common local network protocols,one of which is supported by a subsystem 140 that is embedded in theCPU. In embodiments, the application (see below) gets the measurementsfrom any and all light measurement sensors defined or ‘known’ to it anduses these measurements in reporting the light level for lightscontrolled by the sensor(s) via networking methods previously discussed.

FIG. 17 provides a screenshot of a top level display shown in a UI (userinterface) of the automatically-controlled lighting application. The toplevel display provides a ‘quick recap’ of the status of the user'slighting. In the embodiment shown, the system status is ‘OK’, meaningthere are no issues, the application is managing eight lights and foursensors, the current illumination level is 80, and multiple sensors arecontrolling the lights. The application displays its name andmaintenance level in a header area 142 near the top of the display, andprovides three sub-functions: View/maintain the known lights 144,view/maintain the known sensors 146, and change the brightness or thesensor control over the lights via a ‘setup’ feature 148.

In FIG. 18, a view the application UI presents to the user of all theknown lights is shown. The known lights are listed in ascendingsequential light ‘Name’, which is a user-chosen field. If the lightshown is new and has not been assigned a ‘Name’, the user can tap on the‘Name’ field and enter it. For each light that is known, the light'sserial number and controlling sensor, if any, are shown. As theconfiguration changes:

-   -   if lights are unplugged, the application may note the change to        the user or may simply continue to show the known lights        remaining;    -   if lights have been renamed, the application may note the        light's old and new names to the user, or may simply display the        light's new name in the known light list.

In FIG. 19, a view the application UI presents to the user of all theknown sensors is shown. The known sensors are listed in ascendingsequential sensor ‘Name’, which is a user-chosen field. If the sensorshown is new and has not been assigned a ‘Name’, the user can tap on the‘Name’ field and enter it. For each sensor that is known, the sensor'sserial number and controlled light(s), if any, are shown. As theconfiguration changes:

-   -   if sensors are removed, the application may note the change to        the user or may simply continue to show the known sensors        remaining;    -   if sensors have been renamed, the application may note the        sensor's old and new names to the user, or may simply display        the sensor's new name in the known sensor list.

In FIG. 20, a view the application UI presents to the user for modifyingthe system-wide configuration is shown. In embodiments, the currentillumination level 156 is shown, along with two ‘lower’ and ‘higher’buttons, and the user can tap or click the buttons to change the lightlevel, or can tap the number and enter a new light level value via theapplication's keyboard. In embodiments, the option of using one sensorto control all lights or using multiple sensors to control individuallights 158 is shown, and the user can tap the “Change” button to switchfrom one method to the other.

In FIG. 21, the steps performed by program code executing on a light'sCPU are shown. In the embodiment shown, beginning at the time ofpower-on 160, the CPU may:

-   -   read its Serial Number from Flash memory 162;    -   read the last-used light level from Flash memory 164;    -   set the starting/about-to-be current light level as the        last-used light level 166;    -   set the timer interval, in embodiments, somewhere between 10 ms        and 10 s 168;    -   look for ‘set the level’ commands received by the light from the        application via the common Networking protocol(s) 170;    -   if ‘set the level’ commands were found 172, process them to        change the light level chronologically 174; and    -   broadcast the light's serial number, ‘Name’, and current light        level setting using the common Networking protocol(s) 176.

In FIG. 22, the steps followed by performed by program code executing ona sensor's CPU are shown. In the embodiment shown, beginning at the timeof power-on 178, the CPU may:

-   -   read its Serial Number from Flash memory 180;    -   set the timer interval, in embodiments, somewhere between 10 ms        and 10 s 182;    -   measures the voltage across the ADC subsystem's pin of the CPU        184; and    -   broadcast the sensor's serial number, ‘Name’, and current light        level using the common Networking protocol(s) 186.

1. An LED light, comprising: at least one LED (light-emitting diode); atleast one heat dispersion device to dissipate said LED's heat; at leastone type of cooling apparatus to cool said heat dispersion device; adimmer, wherein said dimmer comprises one of: manually operated; andprogrammatically controlled; at least one rectifier; at least onenon-volatile storage device; at least one analog-to-digital converter; apositioning-fixative device comprising a hex head bolt; and at least oneprocessor comprising program code for controlling said light and saidcooling apparatus.
 2. The LED light of claim 1, wherein each of said atleast one heat dispersion device comprises one of: a heat sink; aradiator; and heat dispersal fins.
 3. The LED light of claim 1, whereineach of said at least one processor comprises one of: a microprocessor;a microcontroller; and a CPU.
 4. The LED light of claim 1, wherein saidprogram code for controlling said light and said cooling apparatuscomprises program code for giving users the ability to view any of: thelight's serial number; the light's user-assigned ‘Name’, if any; and thelight's current light output level, measured using empirical measurementunits.
 5. The LED light of claim 1, wherein said light further comprisesat least one enclosure defining at least one interior space forreceiving: said LED; said heat dispersion devices; said coolingapparatus; said apparatus that performs said dimming function; saidnon-volatile storage device; said rectifier; said analog-to-digitalconverters; and said processor.
 6. The LED light of claim 1, whereinsaid light communicates with the internet using a processor runningprogram code for communications using common networking protocols. 7.(canceled)
 8. The LED light of claim 1, wherein said light is configuredfor use with a grid system, and wherein said light is vertically movablewithout any additional mechanism other than the grid system.
 9. The LEDlight of claim 1, wherein said light can be dimmed either via: manualdimming using manually-operated, self-contained components; andautomatic dimming using light level data.